Pull Stud Fit Detection in Tool Magazines for Reliable Machining
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Solution Overview
Problem
Existing machine tools lack an effective method to determine whether a pull stud is appropriately fitted, leading to potential processing errors due to variations in the pull stud's shape and size, which can affect the fixing force and quality of workpiece processing.
Innovation Solution
A machine tool system that includes a tool magazine, a spindle, and a controller using visual sensors and other detectors to capture and analyze data on the pull stud's dimensions, electric resistance, and capacitance to determine if the pull stud is correctly fitted, with a robot controller moving the visual sensor to capture images and ensure proper attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual sensors and other detectors are used to detect pull stud fitting, then the reliability of processing is improved, but the device complexity increases
Solution Approach 1:
The system performs pull stud fitting detection before tool attachment to the spindle. The controller determines whether the pull stud is appropriately fitted by comparing detected data (visual sensor images or sensor measurements of length, electric resistance, or electric capacity) against predetermined standards, preventing erroneous tools from being mounted in the first place.
Solution Approach 2:
The invention replaces manual inspection or simple mechanical checking of pull stud fitting with automated sensing systems. Visual sensors capture images of the pull stud, while other sensors measure physical properties (length, electric resistance, electric capacity), and the controller automatically processes this data to determine fitting appropriateness, eliminating the need for complex mechanical measurement devices.
2Device complexity
If manual inspection of pull stud is performed, then the device complexity is reduced, but the manufacturing precision deteriorates
Solution Approach 1:
The system replaces manual inspection with automated sensing and control. The controller processes data from visual sensors and other detectors to objectively determine pull stud fitting, eliminating human error and subjectivity while maintaining relatively simple device architecture through the use of standard sensor components.
Solution Approach 2:
The visual sensor creates an optical copy (image) of the pull stud, which the controller then analyzes to determine fitting appropriateness. This allows for precise measurement and evaluation without requiring complex physical measurement devices, as the image data can be processed digitally to extract dimensional and positional information.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system reliably detects abnormalities in the pull stud's fit, preventing processing errors by ensuring the correct fixing force is maintained, thus enhancing the quality of workpiece processing and reducing the risk of tool damage.
Implementation Method 1
a visual sensor which is provided inside or outside the machine tool and which captures images of the pull stud of the tool
Implementation Method 2
a sensor which is provided in the tool magazine and which measures length, electric resistance, or electric capacity of the pull stud
Implementation Method 3
a sensor which is provided in the tool magazine and which measures length, electric resistance, or electric capacity of the pull stud
Data Source
AI summary
A machine tool for machine processing workpieces by using a tool having a pull stud at a proximal end portion thereof. The machine tool includes a tool magazine having a number of tool holders each of which is capable of attaching and detaching the tool, a spindle which holds the tool at the time of machine processing the workpieces, and a controller which determines whether or not the pull stud is appropriate on the basis of detected data of a visual sensor which is provided inside or outside the machine tool, and which captures images of the pull stud of a tool holder of the tool, or detected data of a sensor which is provided inside the tool magazine, and which measures length, electric resistance, or electric capacity of the pull stud.